Electrical device with teeth joining layers and method for making the same

ABSTRACT

A process of making an article of manufacture, the process including constructing an electrical device which implements circuitry having a portion in cavities, the portion defined by an epoxy dielectric material delivered with solid content sufficient that etching the epoxy forms cavities located in, and underneath an initial surface of, the dielectric material, sufficient that the etching of the epoxy uses non-homogeneity with the solid content in bringing about formation of the cavities and sufficient that the etching of the epoxy is such that a plurality of the cavities have a cross-sectional width that is greater than a maximum depth with respect to the initial surface, wherein the etching forms the cavities, and a conductive material, a portion of the conductive material in the cavities thereby forming teeth in the cavities, such that the conductive material forms the portion of the circuitry of the electrical device.

I. CLAIM OF PRIORITY

The present patent application is a continuation of, and incorporates byreference as if fully restated herein, U.S. patent application Ser. No.12/363,501, filed Jan. 30, 2009, pending. Ser. No. 12/363,501 is acontinuation of and incorporates by reference as if fully restatedherein, Ser. No. 10/790,363, filed Mar. 1, 2004, issuing Mar. 10, 2009,as U.S. Pat. No. 7,501,582. Ser. No. 10/790,363 is a continuation of andincorporates by reference as if fully restated herein, Ser. No.09/694,099, filed Oct. 20, 2000, issuing on Mar. 2, 2004, as U.S. Pat.No. 6,700,069. Ser. No. 09/694,099 is a continuation of and incorporatesby reference as if fully restated herein, Ser. No. 08/905,619, filedAug. 4, 1997, issuing on Nov. 7, 2000, as U.S. Pat. No. 6,141,870. Thepresent patent application incorporates by reference all of the patentapplications and patents listed above.

II. FIELD OF THE INVENTION

The present invention is directed to methods for making or manufacturingan electrical device, and the process, composition, and product thereof.More particularly, the present invention involves such multilayerelectrical devices as circuit boards constructed by joining a dielectricmaterial to a subsequently applied conductive material. Still moreparticularly, the present invention involves an electrical device havinga substrate or base, an applied dielectric material thereon, which inturn has a thin conductive coating thereon, and a conductive layerformed upon the conductive coating, the conductive layer being joined tothe applied dielectric material in an improved manner.

III. BACKGROUND OF THE INVENTION

Multilayer electrical devices—those made from layering a dielectricmaterial and a conductive material on a base—suffer from delamination,blistering, and other reliability problems. This is particularly truewhen the laminates are subjected to thermal stress.

Known attempts to solve these problems seem to have focused on physicalor chemical roughening, particularly of the base or substrate. See forexample, U.S. Pat. No. 4,948,707. Although oxide-related chemicalroughening processes have been used, an emphasis on physical rougheningmay reflect the use of materials that are relatively chemicallyresistant. Both physical and chemical roughening approaches haveimproved adherence to the base.

However, the extent to which this adherence can be increased byroughening has its limits. And despite a long standing recognition ofdelamination, blistering, and reliability problems, and the attempts tofind a solution, these problems have been persistent in electricaldevices made of layered materials.

IV. SUMMARY OF THE INVENTION

The inventors herein have observed that the general problem of pooradherence between the laminates or layers can be addressed by forming aunique surface structure, which is particularly suitable for joining thedielectric material to the conductive coating and conductive layer. Thesurface structure is comprised of teeth that are preferably angled orhooked like fangs or canine teeth to enable one layer to mechanicallygrip a second layer.

In comparison with the above-mentioned roughening techniques of theprior art, it is believed that a surface of the teeth is an improvementin that there is an increase in surface area. However, it is stillbetter to use teeth that are fang-shaped to enable a mechanical gripthat functions in a different manner than adherence by means ofincreased surface area. By using the fanged, angled, canine, orotherwise hooked teeth (in addition to increased surface area), there isa multidirectional, three dimensional interlacing or overlapping oflayers. For example, in joining the dielectric material to theconductive coating and metal layer, the conductive coating and metallayer is actually burrowed in and under the dielectric material and viceversa. Thus, separating them not only involves breaking the surface areaadherence, but also involves destroying the integrity of at least one ofthe layers by ripping the teeth, the layer pierced by them, or both.

Further, it has been found preferable to have numerous teeth sized andshaped so that they are not too large or too small. If the teeth are toosmall, wide, straight, and shallow, then the surface resembles theroughened surface of prior art techniques, vaguely analogous to asurface of molar teeth, and the adherence is not much better than thatachieved by known prior art roughening techniques.

However, if the teeth are too large, deep, and fanged or hook-shaped,the teeth undercut the surface to such an extent that the strength ofthe dielectric material surface is weakened. As a result, adherence isdecreased over the preferred embodiment.

Not too great and not too slight, the right sized and shaped teeth, setin a fanged orientation and with sufficient frequency, have been foundto be the best structure. If the correct balance of these criticallyimportant factors is created, the result is a greatly improved circuitboard or other such electrical device.

It is theorized by the inventors that the best methods for producing theteeth is to use non-homogeneous materials and/or techniques. Forexample, a dielectric material can have a non-homogeneous composition orthickness to bring about an uneven chemical resistance, such that slowedand/or repeated etching will form teeth instead of a uniform etch.

V. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a conductive coating and metal layerapplied dielectric material with a desirable tooth structure;

FIG. 2 is an illustration of a prior art conductive coating and metallayer on the applied dielectric material with the surface produced byroughening processes;

FIG. 3 is an illustration of a double sided printed circuit boardwithout plated through holes;

FIG. 4 is an illustration of a multilayer printed circuit board withplated through holes, filled or unfilled with conductive ornonconductive material;

FIG. 5 is an illustration of a multilayer printed circuit board withoutplated through holes;

FIG. 6 is an illustration of a multilayer printed circuit board havingmore than two layers with plated through holes filled or unfilled withconductive or nonconductive material;

FIG. 7 is an illustration of any of the foregoing printed circuit boardsafter applying a dielectric material thereon;

FIG. 8 is an illustration of the multilayer printed circuit board ofFIG. 7 after forming micro vias;

FIG. 9 is an illustration of the multilayer printed circuit board ofFIG. 7 after opening the through holes and after etching the applieddielectric material to produce the teeth illustrated in FIG. 1;

FIG. 10 is an illustration of the multilayer printed circuit board ofFIG. 9 after application of a conductive coating to fill in around theteeth and connect micro via holes and the through holes; and

FIG. 11 is an illustration of the multilayer printed circuit board ofFIG. 10 after plating the conductive coating to form a metal layer andcomplete forming circuitry.

VI. DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a conductive coating and metal layer on theapplied dielectric material with a desirable tooth structure. Incontrast, FIG. 2 is an illustration of a prior art conductive coatingand metal layer on the applied dielectric material with the surfaceproduced by roughening processes. Both FIGS. 1 and 2 show a dielectricmaterial and a combination of a thin conductive coating and metal later.Compare FIG. 1 and FIG. 2, and note particularly the size, shape,frequency, and depth of the teeth 11 in FIG. 1 with the surface producedby roughening in FIG. 2.

A way of articulating this “teeth” concept is to view each tooth asbeing made of one layer and set in a second layer. However, theperspective is arbitrary, and one could equally view each tooth as madeof the second layer set in the first. It could also be said that thelayers join in a saw-toothed manner, i.e., teeth made of both materialsin an interlocking bite. In any case, however, there are teeth, and forthe sake of consistency, this specification will adopt the convention ofreferring to the teeth as being made of the conductive coating and metallayer set in the dielectric material.

A further way of articulating the “teeth” concept is to view each toothas being substantially triangular in shape, with the base of thetriangle being defined by a plane of the applied dielectric materialbefore it is etched, or more precisely by the exterior surface thereof.The invention can be carried by forming cavities in the applieddielectric material 6 for receiving the teeth, and then forming theteeth from the conductive coating and metal layer formed thereon.Generally, the teeth can be of any triangular shape (e.g., equilateral,isosceles, scalene, right, obtuse, or any combination thereof).Preferably, though, the teeth are obtuse so as to hook or angle underthe exterior surface of the applied dielectric material.

The use of any shape of teeth increases the surface area where theconductive coating is on the applied dielectric material. However, thepreferred embodiment utilizes a surface of obtuse, canine, orfang-shaped teeth to help the conductive coating and metal layer hookunder the exterior surface of the applied dielectric material tomechanically grip the applied dielectric material. The obtuse, canine,or fang-shaped teeth are in contrast to the shallower, more roundedsurface typically produced by known roughening techniques. Note in FIG.2 that roughing techniques can produce some occasional gouging, butnothing on the order of the present invention.

As to size of the teeth, as mentioned above, it is preferable that theteeth be within a certain size range. The optimal size range for obtuse,canine, or hook-shaped teeth involves a balance between maximizingsurface area and mechanical grip, but not undercutting the surface ofthe applied dielectric material 8 to such an extent as to weaken it.Accordingly, the teeth should be sized at least 1 tenth of a mil deep.Better is at least 1.25 tenths of a mil deep, and even better is atleast 1.5 tenths of a mil deep. However, 1.75 tenths of a mil isacceptable, and about 2 tenths of a mil is reaching the limit.

As to frequency, the teeth should be quite frequent in number; at leastabout 5,000 teeth per linear inch, and preferably at least about 10,000teeth per linear inch; and even better is at least about 15,000 teethper linear inch.

As to surface area, there should be at least about 25,000 teeth persquare inch, better still is essentially at least about 100,000 persquare inch, and preferably at least about per 200,000 per square inch,or even greater.

It should be recognized that the teeth generally are not formed to aprecise dimension. As shown in FIG. 1, some of the teeth are somewhatdifferently sized, angled, and proportioned. Thus, a representativesample of the electrical device should have teeth in about these ranges.Having at least about 20% of the teeth in one or more of these ranges,and preferably at least 50%, is a preferred balance of mechanical gripwithout a weakening the integrity of the layering, particularly incombination.

As illustrated in FIGS. 3-11, there is an electrical device, such as aprinted circuit board 2 having a base 4. The base 4 has a conductivelayer 6 thereon. A dielectric material 8 is applied on the conductivelayer 6, and a conductive coating 10 (such as a thin coating ofpalladium) is deposited on the dielectric material 8. Metal layer 12 isformed on the conductive coating 10.

FIG. 3 illustrates one of the many ways to begin the process of formingthe teeth in accordance with the present invention. A first step (step1), includes providing a base 4 for constructing an electrical device,such as a printed circuit board 2. FIG. 3 illustrates one suchconstruction, namely a base 4 for constructing a multilayer printedcircuit board 2, the base 4 having any positive number of layers orlaminates, for example the two layers shown in FIGS. 3 and 4, or morethan two layers as illustrated in FIGS. 5 and 6, etc. One configurationor another is not significant, except that multiple layers provide abetter medium for constructing circuitry of increased complexity ordensity. FIGS. 3-6 illustrate an embodiment in which the conductivelayer 6 is on at least an upper side, and preferably also on a lowerside of the base 4.

As may be needed for a particular circuitry design, FIG. 4 illustratesthat the electrical device can be further manipulated, for example, byforming through holes 12 by mechanical drilling, laser drilling,punching, or the like. The plated through holes 12 are shown in FIGS. 4and 6 as filled or unfilled with a conductive or a nonconductivematerial.

FIG. 5 illustrates a configuration for the multilayer printed circuitboard 2 with base 4 having more than two layers or laminates, theconductive layers 6 located there between.

FIG. 6 shows the multilayer printed circuit board 2 after forming,plating, and if needed, filling the through holes 12 in the manner ofFIG. 4.

To summarize, step 1 of the process includes providing a base 4 forforming an electrical device such as a printed circuit board 2, whereinthe base 4 can be formed to have one or more layers or laminates. Atleast one conductive layer 6 is on the base 4. The base 4 can be doublesided with the conductive layer 6 being located outside the base 4 andbetween the layers or laminates.

The printed circuit board 2 can be further prepared, as may be desirablefor a particular circuitry design, by forming open through holes 12 andplating and if needed, filling the through holes 12 to electricallyconnect to that portion of the conductive layer 6 appropriate forwhatever circuitry design is being constructed, e.g., each side of adouble sided circuit board 2. In other words, step 1 involves providingone of the configurations described in FIGS. 3-6.

Step 2 includes preparing an outer-most surface of the conductive layer6 for any of the above-mentioned configurations. The step of preparingis carried out to enable adherence, e.g., of the applied dielectricmaterial 8 to the conductive layer 6, preferably in a manner thatutilizes a respective tooth structure. The step of preparing can becarried out, for example, by using an oxide or an oxide replacementprocess to treat the conductive layer 6 to such an extent that the teeth(or cavities for teeth) are formed.

As to using an oxide process, a copper oxide can be chemically depositedon a copper surface to produce a tooth-like structure on the surface ofthe copper. This process is carried out to prepare the copper surfaceprior to applying another layer of material, thereby providing increasedbond strength between the two materials.

As to using an oxide replacement process to form a tooth structure, amicro etch on the surface of the copper is followed by a coating of anadhesion promoter to enhance a bond between copper and the dielectricmaterial 8. For example, Alpha Metals, Inc. offers a PC-7023 productwhich is suitable for an oxide replacement process.

Step 3 includes applying the dielectric material 8 to the outermostsurface of the conductive layer 10 (and the base 4 if appropriate forthe circuitry or electrical device at issue) prepared in accordance withthe step 2. The dielectric material 8 can be applied by as a (dry) film,a (liquid) curtain coating, a (liquid) roller coating, or an analogousapplication or bonding technique. FIG. 7, in comparison with FIGS. 3-6,illustrates the dielectric material 8 on the outermost surface(s) of theconductive layer 4 (and the base 2).

Step 4 includes preparing the applied dielectric material 8 for receiptof a conductive coating 10, which to exemplify, is detailed moreparticularly below. Generally, though, the preparing step 4 can includeexposing, developing, and curing the applied dielectric material 8 toform patterns for further construction of the circuitry, including suchfeatures as constructing a via or photo via 14, for optionally fillingby conductive or non-conductive materials, e.g., screened, rollercoated, etc. Compare FIGS. 6 and 7.

Step 5 includes forming open through holes 16 as shown in FIG. 9. Asindicated above with regard to filled through holes 12, the open throughholes 16 can be formed by such methods as drilling, boring, punching,and the like.

Step 6, as discussed subsequently in greater detail, involves theetching cavities, veins, openings, or gaps in the applied dielectricmaterial 8, or more particularly an outermost surface thereof, toaccommodate the teeth. One technique for forming the teeth is somewhatsimilar to what has been known as the swell and etch or desmear process,except that contrary to all known teachings in the prior art, in effect,a “double desmear process” is utilized. That is, not merely increasingthe times and temperatures and other parameters for the desmear process,but instead completing the process a first time, and then completing theprocess a second time. Consider using the following Shipley products forthe double desmear process: CIRCUPOSIT MLB conditioner 211, promoter213B, and neutralizer 216. Non-homogeneous materials and/or processesseem to be determinative.

Step 7 includes applying a conductive coating 10 to the cavities in theapplied dielectric material 8. The conductive coating 10 is also appliedto the photo-defined via holes 14 and the open through holes 16.Techniques for applying the conductive coating 10 include a direct plateprocess or an electroless copper process. To carry out the presentinvention, it is preferable to use a palladium-based direct plateprocess or other non-electroless process. In this regard, a Crimsonproduct of Shipley is suitable, though the desmear process as disclosedherein is contrary to the manufacturer's specifications, i.e., a “doubledesmear process,” rather than the single desmear process of the knownprior art. Compare FIGS. 1, 2, and 9.

Step 8 includes forming a metal layer 18 on the conductive coating 10,by such metal deposition techniques as electrolytic or non-electrolyticplating, to form the tooth structure and teeth as discussed above. Themetal layer 18 and conductive coating 10 collectively form circuitry onthe outermost surface of the applied dielectric material 8, which canconnect to whatever portion of conductive layer 6 as may be needed for aparticular design, preferably by making at least one connection througha micro via. See FIG. 10. A direct plate process, followed as needed bysay a semi-additive or fully additive pattern plating process, isrecommended.

A direct plate process is a replacement for traditional electrolesscopper plating of non-conductive surfaces. Direct plate processes applya very thin conductive coating (e.g., using palladium or graphite) tothe non-conductive surface, thus enabling electroplating of copper orother conductive material onto the previously non-conductive surface.Thus, “direct plate” is used to describe directly plating onto anon-conductive surface without first requiring a non electrolytic(electroless) plating process.

A semi-additive plating process involves first electroplating a thinconductive layer onto the total non-conductive surface, before applyinga photoresist and subsequently pattern plating the required circuitry.For semi-additive plating, the thin conductive layer must be removed(etched) from the non-conductive surface. For fully additive plating,photoresist is applied directly on the non-conductive surface, followedby pattern plating the required circuitry (after applying the thinconductive coating in the direct plate process). That is, the fullyadditive plating forms only the required circuitry and requires noetching.

It should be recognized that the present invention can optionally becarried out by initially skipping step 5 (forming the open through holes16) during initial “sets” of the foregoing steps, i.e., completing steps6 and 7; then repeating steps 2 through 8, again skipping step 5 eachtime until the last set of steps, as required to form the electricaldevice or circuitry of interest. This will produce an electrical devicewith a second tooth structure that is not set in the first layer ofdielectric material 8, and indeed the idea of using a toothed structureis not limited to any one layer and is best employed in holding multiplelayers together. Step 5 can be carried out after the desired layers havebeen formed.

Turning now more particularly to the process for forming the teeth andthe cavities for the teeth, the present invention can be carried out bya new use of a Ciba-Geigy product known as Probelec XB 7081 as aphotoimagable dielectric material 8. Generally, and in accordance withits specification sheet, Probelec XB 7081 is a single component, 100%epoxy photodielectric material specially developed for Sequential BuildUp (SBU) of multilayer boards.

Probelec XB7081 is a negative working, high resolution liquidphoto-imageable (LPI) material which allows mass-forming of micro viasfor fabrication of high-density interconnects (HDI). Compatible withconventional plating and circuitization techniques, Probelec XB 7081also provides outstanding electrical and physical properties for mostcircuit board applications, and is compatible with most circuit boardsubstrate materials.

Probelec XB 7081 is specially developed to act as a dielectric betweencircuit layers in fabrication of blind and buried micro via MLBS. Thehigh resolution photo dielectric allows mass forming of micro vias forthe construction of high density interconnects. Probelec XB 7081 haswide process latitudes, excellent handling characteristics, and is knownas self-leveling and having an adjustable dry thickness of 1-3 mils.Probelec XB 7081 has a high resolution capability of 1-2 mil micro vias,and is known for chemical resistance, even for additive plating; thereare excellent electrical and physical properties and a UL 94V-0 rating.Probelec is specified to demonstrate more than a 6 lb/in peel strength.By application of this invention this peel strength should besignificantly increased due to the formation of the teeth. Accordinglythe peel strength produced in accordance with the present invention isgreater than the peal strength produced by the desmear process of theprior art, i.e., a single pass desmear process. For example, if a priorart desmear process is used to produce a 6 lb/in average peel strength,the present invention may produce an average peel strength on the orderof 10 lb/in or more.

As to the general properties of Probelec XB 7081, there is a storagestability (1-component system) for more than 6 months at 25° C.; the potlife in a coater machine is more than 1 week; the hold time of thecoating is more than 1 week (dark or exposed) and more than 1 day inyellow light.

When using Probelec XB 7081 to carry out the above-mentioned step 3 ofapplying a coating of the dielectric material, there is a pre-cleaningsub-step A. Pre-cleaning should be carried out in chemical, mechanicalbrushing, or pumice spray units. Extra precaution is needed to ensurethat the pre-cleaning equipment and chemistry is not contaminated bymaterials from previous processing steps. Contrary to Cibaspecifications, it is preferred to use an oxide or oxide replacement toprepare the surface prior to applying a coating of the dielectric. Holdtimes after pre-cleaning should be minimized to avoid oxidation ofcopper surfaces. In all coating applications, pre-cleaned substratesshould be free of particles. Additional cleaning steps, e.g., withdetergents, may be required to remove organic residues.

Next there is a coating sub-step B. Probelec XB7081 seems to have beenprimarily designed for curtain coating and is delivered with a solidcontent of 58%. Substrates should be heated to about 40° C. prior tocoating to ensure all residual moisture is removed and to preparesubstrate for curtain coating. For initial charging of a coater machine,Probelec XB 7081 needs to be premixed with about 15% of PMA (PMA is1-methoxy-2-propyl acetate) to ensure proper viscosity. The additionalPMA thins the coating down to about 50% solids.

The resin temperature should be 25±1° C., with a conveyor speed of 90m/min. The viscosity is at 25° C., DIN AK4 cup at 60 sec. (400 cps),with a coater gap width of 500 mm. The wet weight is 7.5-10.0 gms/600 CMsq. and 11.6-15.5 gms/ft sq. The dry thickness is 45-60 mm.

Next is a flash dry sub-step C. Coated panels must be held in ahorizontal position under dust-free conditions to air dry. At thisstage, minimal air flow is recommended. The drying time is 12-18 min. ata drying temperature of 30-40° C.

Next is a final dry sub-step D. After flash air drying, final drying atan elevated temperature is needed to achieve better than 95% removal ofsolvents for tack-free handling. This can be accomplished in batch orconveyorized tunnel ovens, as follows:

Tunnel Oven Batch Oven Drying Temperature: 130-140° C. 90° C. DryingTime: 2-3 minutes 30 minutesAfter cooling, the panels can have a second side coating (sub-steps Athrough D) if appropriate for the circuit design, and then for anexposure sub-step E.

In the exposure sub-step E, catalyst for cross linking of epoxy resin isgenerated. The main spectral sensitivity of Probelec XB 7081 is in therange of 350-420 nm. Conventional exposure units, collimated ornon-collimated, with peak spectral emission of 365 nm are recommended.Both diazo and silver halide films are suitable as working phototools.Good artwork to coating contact is essential for consistent micro viareproduction. The exposure energy is 1200-1600 mJ/cm sq. and theexposure time (7 kW) is 30-40 seconds. The Stouffer Step (21 scale) is5-7.

Next is a thermal bump step F. Thermal bump provides the energy forcrosslinking the catalyzed epoxy resin. This process can be done inconvection batch or conveyorized tunnel ovens. For a batch oven, 110° C.for 60 min. is appropriate, and for a conveyorized tunnel oven, 130° C.for 10-20 min. is appropriate.

Next is a developing sub-step G. The unexposed areas of Probelec XB7081are developed away in continuous spray developing machines. Variousmodels with different processing capacities are available for thispurpose. A Ciba-Geigy product DY 950 (Gamma-Butyrolactone (GBL))developer is recommended for processing Probelec XB7081. This developeris a halogen-free, high-boiling organic solvent suitable for on-sitedistillation or recycling. Probimer 450/470 spray developing equipmentis specially designed for use with this developer solution. Thetemperature is 20±2° C., and the spray pressure is 2-4 bar. The speedfor Probimer 450 is 2-3 m/min; for Probimer 470, 3-4 m/min.

Next is a final cure sub-step H. Final thermal curing is needed toimpart good mechanical, chemical, and electrical properties to thedielectric film. The thermal curing can take place in batch orconveyorized tunnel ovens. The thermal curing temperature is 150° C.,with a thermal curing time of 60 minutes.

Next can come the step 5 of further preparing, for example, by formingthrough holes 16. If plated through holes 16 (PTH's) are needed forinterconnecting layers to the bottom or back side of the printed circuitboard 2, drilling should of course be done before plating. This allowsthe plating of the surface together with the through holes 16. Platingand such post-processing of the photoimagable dielectric material 8 isdependent on particular process preferences. Probelec XB7081 iscompatible with panel-plate, pattern-plate or additive plating.

The following process sub-steps of the above-mentioned step 6 describe ageneric sequence for a desmear process to form cavities in thedielectric. Although Probelec XB7081 apparently was intended for use inthe common desmear (swell and etch) process as used in conventionalplated through hole plating lines, Probelec XB7081 can alternatively beused in carrying out the present invention. For example, the presentinvention differs from the common desmear process in that sub-steps inthe desmear process are repeated as a way of forming the teeth. Sub-stepA, swelling the dielectric material 8, can be carried out with butyldiglycol/sodium hydroxide/water 80° C. for 3-5 minutes. Sub-step B isrinsing the dielectric material 8 in deionized water at room temperaturefor 4 minutes. Sub-step C is etching the dielectric material 8, whichcan be carried out using potassium permanganate/sodium hydroxide/water80° C., 6-10 minutes. Sub-step D is rinsing the dielectric material 8 indeionized water at room temperature for 4 minutes. Sub-step D includes afurther rinsing of the dielectric material 8 in deionized water at roomtemperature for 4 minutes. Sub-step E is neutralizing the dielectricmaterial 8 in sulfuric peroxide (1.5%) for 3 to 5 minutes. Finally stepF is rinsing the dielectric material 8 in deionized water at roomtemperature for 4 minutes.

In stark contrast with the etch and swell process of the known priorart, however, a second pass through the process (sub-steps A through F)is used. The second pass seems to make use of non-homogeneities inbringing about a formation of the teeth. Thus, unlike the prior swelland etch chemical roughening process, which produces a surfacecharacterized by a surface gloss measurement at an angle of 60° which isbetween 15 and 45%, the present invention has less gloss (<10%).

Turn now in greater detail to the step 7 of applying the conductivecoating 10 for subsequent deposition of the metal layer 18 by, say,plating. Good results can be achieved with a flash plate of 0.7-1.0 mm(30-40 micro inches). The flash plate is followed by baking at 130-150°C., for 2 hours.

For pattern plating, plating resist can be applied after baking.Depositing the metal layer 18 by electroplating can be carried out suchthat there is 10-25 mm (0.4-1.0 mil.).

While a particular embodiment of the present invention has beendisclosed, it is to be understood that various different modificationsare possible and are within the true spirit of the invention, the scopeof which is to be determined with reference to the claims set forthbelow. There is no intention, therefore, to limit the invention to theexact disclosure presented herein as a teaching of one embodiment of theinvention.

We claim:
 1. A process of making an article of manufacture, the processcomprising: implementing a circuit design for an electrical device bycoupling an epoxy dielectric material delivered with solid contentsufficient that etching the epoxy forms a non-uniformly roughenedsurface of angular tooth-shaped cavities located in, and underneath aninitial surface of, the dielectric material, sufficient that the etchingof the epoxy uses non-homogeneity with the solid content in bringingabout formation of the non-uniformly roughened surface of the angulartooth-shaped cavities and sufficient that the etching of the epoxy issuch that a plurality of the cavities have a cross-sectional width thatis greater than a maximum depth with respect to the initial surface,wherein the etching forms the non-uniformly roughened surface of angulartooth-shaped cavities, with a conductive material, a portion of theconductive material in the cavities thereby forming angular teeth in thecavities, in circuitry of the electrical device.
 2. The process of claim1, wherein some of the cavities comprise veins.
 3. The process of claim1, wherein the cavities comprise cavities which substantially exhibitone or more of the following shapes: fanged, canine, and otherwisehooked teeth.
 4. The process of claim 1, wherein the cavities comprisecavities which substantially exhibit one or more of the following angledshapes: equilateral, isosceles, scalene, right, obtuse, or anycombination thereof.
 5. The process of claim 3, wherein the cavitiescomprise cavities which substantially exhibit one or more of thefollowing angled shapes: equilateral, isosceles, scalene, right, obtuse,or any combination thereof.
 6. The process of claim 1, wherein aconductive layer is intermediate the conductive material and thedielectric material, and wherein the bringing about the formation of thenon-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.7. The process of claim 6, wherein at least one of the teeth has a depthin a range of 1 tenth of a mil and less than about 2 tenths of a mil. 8.The process of claim 6, wherein a sample of the circuitry has at leastabout 5,000 of the teeth per linear inch.
 9. The process of claim 1,wherein the portion of the circuitry is multilayer circuitry of theelectrical device.
 10. The process of claim 1, wherein the electricaldevice is a circuit board.
 11. The process of claim 1, wherein theportion of the conductive material is connected to a second portion ofthe conductive material through at least one micro via.
 12. The processof claim 1, wherein the conductive material comprises a micro via in amulti-layer circuit board.
 13. A process of making an article ofmanufacture, the process comprising: implementing a circuit design foran electrical device by coupling an epoxy dielectric material deliveredwith solid content sufficient that etching the epoxy forms anon-uniformly roughened surface comprising cavities located in, andunderneath a surface of, the dielectric material, and sufficient thatthe etching of the epoxy uses non-homogeneity with the solid content inbringing about formation of the non-uniformly roughened surface with atleast some of the cavities having a first cross-sectional distanceproximate the surface and a substantially greater cross-sectionaldistance distant from the surface, with a conductive material, wherebythe etching of the epoxy forms the cavities, and a portion of theconductive material in the cavities thereby forming teeth in thecavities, wherein the etching of the non-homogeneous composition formsthe cavities, in circuitry of the electrical device.
 14. The process ofclaim 13, wherein the substantially greater cross-sectional distance isat least twice the first cross-sectional distance.
 15. The process ofclaim 13, wherein the electrical device is a circuit board.
 16. Aprocess of making an article of manufacture, the process comprising:implementing a circuit design for an electrical device by coupling anepoxy dielectric material delivered with solid content sufficient thatetching the epoxy forms a non-uniformly roughened surface comprisingsubstantially molar-shaped cavities located in, and underneath aninitial surface of, the dielectric material and sufficient that theetching of the epoxy uses non-homogeneity with the solid content inbringing about formation of the non-uniformly roughened surfacecomprising the molar-shaped cavities and a plurality of the cavitieshave a first cross-sectional distance proximate the initial surface anda substantially greater cross-sectional distance distant from theinitial surface, with a conductive material, a portion of the conductivematerial in the cavities thereby forming teeth in the cavities, whereinthe etching of the epoxy forms the cavities, in circuitry of theelectrical device.
 17. The process of claim 16, wherein thesubstantially greater cross-sectional distance is at least twice thefirst cross-sectional distance.
 18. The process of claim 16, wherein theelectrical device is a circuit board.
 19. A process of making an articleof manufacture, the process comprising: implementing a circuit designfor an electrical device by coupling an epoxy dielectric materialdelivered with sufficient solid content that etching of the epoxy formsa non-uniformly roughened surface of molar-shaped cavities located in,and underneath an initial surface of, the dielectric material andsufficient that the etching of the epoxy uses the non-homogeneity withthe solid content in bringing about formation of the non-uniformlyroughened surface of the molar-shaped cavities and a plurality of thecavities have a first cross-sectional distance proximate the initialsurface and a substantially greater cross-sectional distance distantfrom the initial surface, and a conductive material, a portion of theconductive material in the cavities thereby forming teeth in thecavities, wherein the etching of the epoxy forms the cavities so that aplurality of the teeth each expand below a respective narrower regionwhich is closer to the initial surface, in circuitry of the electricaldevice.
 20. The process of claim 19, wherein the electrical device is acircuit board.
 21. A process of making an article of manufacture, theprocess comprising: implementing a circuit design for an electricaldevice with circuitry comprising means for interlocking a conductor partof the circuitry configured for filling cavities with an epoxydielectric material disposed in combination with the circuitry andcoupled with the conductor part in a configuration where the dielectricmaterial comprises a non-uniformly roughened surface comprising cavitieslocated in and underneath an initial surface of the dielectric materialdelivered with solid content being non-homogeneous and configured tobring about formation of the non-uniformly roughened surface by etchingof the epoxy, at least some the cavities having a first cross-sectionaldistance proximate the initial surface and a substantially greatercross-sectional distance distant from the initial surface.
 22. Theprocess of claim 2, wherein the bringing about the formation of thenon-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.23. The process of claim 3, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.24. The process of claim 4, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.25. The process of claim 5, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.26. The process of claim 7, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.27. The process of claim 8, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.28. The process of claim 9, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.29. The process of claim 10, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.30. The process of claim 11, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.31. The process of claim 12, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.32. The process of claim 13, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.33. The process of claim 14, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.34. The process of claim 15, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.35. The process of claim 16, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.36. The process of claim 17, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.37. The process of claim 18, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.38. The process of claim 19, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.39. The process of claim 20, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.40. The process of claim 21, wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.41. The process of claim 1, wherein the etching includes a first etchingand a second etching.
 42. The process of claim 2, wherein the etchingincludes a first etching and a second etching.
 43. The process of claim3, wherein the etching includes a first etching and a second etching.44. The process of claim 4, wherein the etching includes a first etchingand a second etching.
 45. The process of claim 5, wherein the etchingincludes a first etching and a second etching.
 46. The process of claim6, wherein the etching includes a first etching and a second etching.47. The process of claim 7, wherein the etching includes a first etchingand a second etching.
 48. The process of claim 8, wherein the etchingincludes a first etching and a second etching.
 49. The process of claim9, wherein the etching includes a first etching and a second etching.50. The process of claim 10, wherein the etching includes a firstetching and a second etching.
 51. The process of claim 11, wherein theetching includes a first etching and a second etching.
 52. The processof claim 12, wherein the etching includes a first etching and a secondetching.
 53. The process of claim 13, wherein the etching includes afirst etching and a second etching.
 54. The process of claim 14, whereinthe etching includes a first etching and a second etching.
 55. Theprocess of claim 15, wherein the etching includes a first etching and asecond etching.
 56. The process of claim 16, wherein the etchingincludes a first etching and a second etching.
 57. The process of claim17, wherein the etching includes a first etching and a second etching.58. The process of claim 18, wherein the etching includes a firstetching and a second etching.
 59. The process of claim 19, wherein theetching includes a first etching and a second etching.
 60. The processof claim 21, wherein the etching includes a first etching and a secondetching.
 61. The process of claim 22, wherein the etching includes afirst etching and a second etching.
 62. The process of claim 23, whereinthe etching includes a first etching and a second etching.
 63. Theprocess of claim 24, wherein the etching includes a first etching and asecond etching.
 64. The process of claim 25, wherein the etchingincludes a first etching and a second etching.
 65. The process of claim26, wherein the etching includes a first etching and a second etching.66. The process of claim 27, wherein the etching includes a firstetching and a second etching.
 67. The process of claim 28, wherein theetching includes a first etching and a second etching.
 68. The processof claim 29, wherein the etching includes a first etching and a secondetching.
 69. The process of claim 30, wherein the etching includes afirst etching and a second etching.
 70. The process of claim 31, whereinthe etching includes a first etching and a second etching.
 71. Theprocess of claim 32, wherein the etching includes a first etching and asecond etching.
 72. The process of claim 33, wherein the etchingincludes a first etching and a second etching.
 73. The process of claim34, wherein the etching includes a first etching and a second etching.74. The process of claim 35, wherein the etching includes a firstetching and a second etching.
 75. The process of claim 36, wherein theetching includes a first etching and a second etching.
 76. The processof claim 37, wherein the etching includes a first etching and a secondetching.
 77. The process of claim 38, wherein the etching includes afirst etching and a second etching.
 78. The process of claim 39, whereinthe etching includes a first etching and a second etching.
 79. Theprocess of claim 40, wherein the etching includes a first etching and asecond etching.
 80. An electrical device comprising: circuitry;conductive material being part of the circuitry and configured asangular teeth in filling cavities; and an epoxy dielectric material,disposed in combination with the circuitry and coupled with theconductive material in a configuration where the dielectric materialcomprises a non-uniformly roughened surface comprising cavities locatedin and underneath an initial surface of the dielectric materialdelivered with solid content being non-homogeneous and configured tobring about formation of the non-uniformly roughened surface by etchingof the epoxy, at least some the cavities having a first cross-sectionaldistance proximate the initial surface and a substantially greatercross-sectional distance distant from the initial surface.
 81. Theelectrical device of claim 80, wherein some of the cavities compriseveins.
 82. The electrical device of claim 80, wherein the cavitiescomprise cavities which substantially exhibit one or more of thefollowing shapes: fanged and canine, and otherwise hooked teeth.
 83. Theelectrical device of claim 80, wherein the cavities comprise cavitieswhich substantially exhibit one or more of the following angled shapes:equilateral, isosceles, scalene, right, obtuse, or any combinationthereof.
 84. The electrical device of claim 83, wherein the cavitiescomprise cavities which substantially exhibit one or more of thefollowing angled shapes: equilateral, isosceles, scalene, right, obtuse,or any combination thereof.
 85. The electrical device of claim 80,wherein a conductive layer is intermediate the conductive material andthe dielectric material, and wherein the bringing about the formation ofthe non-uniformly roughened surface does not include bringing aboutformation of cavities in the conductive material by physical roughening.86. The electrical device of claim 80, wherein at least one of the teethhas a depth in a range of 1 tenth of a mil and less than about 2 tenthsof a mil.
 87. The electrical device of claim 80, wherein a sample of thecircuitry has at least about 5,000 of the teeth per linear inch.
 88. Theelectrical device of claim 80, wherein the circuitry comprisesmultilayer circuitry of the electrical device.
 89. The electrical deviceof claim 80, wherein the electrical device is a circuit board.
 90. Theelectrical device of claim 81, wherein the etching includes a firstetching and a second etching.
 91. The electrical device of claim 82,wherein the etching includes a first etching and a second etching. 92.The electrical device of claim 83, wherein the etching includes a firstetching and a second etching.
 93. The electrical device of claim 84,wherein the etching includes a first etching and a second etching. 94.The electrical device of claim 85, wherein the etching includes a firstetching and a second etching.
 95. The electrical device of claim 86,wherein the etching includes a first etching and a second etching. 96.The electrical device of claim 87, wherein the etching includes a firstetching and a second etching.
 97. The electrical device of claim 88,wherein the etching includes a first etching and a second etching. 98.The electrical device of claim 89, wherein the etching includes a firstetching and a second etching.
 99. The electrical device of claim 90,wherein the etching includes a first etching and a second etching. 100.A product produced by the process of
 1. 101. A product produced by theprocess of
 13. 102. A product produced by the process of
 16. 103. Aproduct produced by the process of 21.